Deflection and drift structural wall assemblies

ABSTRACT

Metal framing system composed of stud and track profiles having preformed slots which allow system to accommodate for vertical deflection and horizontal drift/adjustment. Embodiment of the system also used to create protection of fire rated joints in rated wall partitions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. ProvisionalApplication No. 61/280,227 filed on Nov. 2, 2009, which application isincorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The present invention relates generally to structural wall assembliesand, more particularly, to metal flaming structural wall assembliesconfigured to accommodate vertical deflections and horizontal drifts.

BACKGROUND OF THE INVENTION

Metal framing assemblies are commonly used to construct commercial andresidential buildings in the building construction industry Such metalframing assemblies are generally constructed from a plurality of metalframing members including studs, joist, trusses, and other metal postsand beams formed horn sheet metal and frequently fabricated to have thesame general cross-sectional dimensions as standard wood members usedfor similar purposes. Metal framing members are typically constructed byroll-forming 12 to 24 gauge galvanized sheet steel Although manycross-sectional shapes are available, the primary shapes used inbuilding construction are C-shaped studs and U-shaped tracks.

In the building construction trade, a head-of-wall joint (also sometimesreferred to as a top-of-wall joint) refers to the linear junction orinterface existing between a top section of a framing/wallboard wallassembly and the ceiling (where the ceiling may be a next-level floor orcorrugated pan roof deck, for example). In common practice, a wall toceiling connection of many newly constructed buildings consistsessentially of an inverted U-shaped elongated steel channel (or track)configured to receive steel studs between the legs (also sometimesreferred to as sidewalls or flanges) of the shaped channel. A wallboardis generally attached to at least one side of the studs. The studs andwallboard are in many instances spaced apart from the ceiling a shortgap distance in order to allow for ceiling deflections caused by seismicactivity or moving overhead loads. Channel and stud assemblies thatallow for ceiling deflections are commonly referred to as dynamichead-of-wall systems. Exemplary steel stud wall constructions may befound in U.S. Pat. Nos. 4,854,096 and 4,805,364 both to Smolik, and U.S.Pat. No. 5,127,203 to Paquette Exemplary dynamic head-of-wall systemshaving steel stud wall constructions may be found in U.S. Pat. No.5,127,760 to Brady, and U.S. Pat. No. 6,748,705 to Orszulak et al.

Although some advances have been made with respect to structural wallassemblies, there is still a need in the art for new and improvedstructural wall assemblies that can accommodate both verticaldeflections and horizontal drifts. The present invention fulfills theseneeds and provides for further related advantages

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a structural wall assembly inaccordance with an embodiment of the present invention

FIG. 1B is a perspective view of a structural wall assembly inaccordance with an embodiment of the present invention (embodimenthaving intumescent strips affixed lengthwise on the top portion of agenerally U-shaped header track)

FIG. 1C is a perspective view of a structural wall assembly inaccordance with an embodiment of the present invention (embodimenthaving intumescent strips affixed lengthwise on the top portion of agenerally U-shaped header track and wherein the header track alsoincludes an outwardly extending elongated protrusion or groove).

FIG. 2A is a side view of a structural wall assembly in accordance withan embodiment of the present invention

FIG. 2A is a side view of a structural wall assembly in accordance withan embodiment of the present invention wherein the wall assembly isattached to a floor and ceiling.

FIG. 3A is a perspective view of a portion of a structural wall assemblyin accordance with an embodiment of the present invention.

FIG. 3B is a perspective view of a portion of a structural wall assemblyin accordance with an embodiment of the present invention and showing anupward deflection of the header track

FIG. 4 is an exploded perspective view of a portion of a structural wallassembly in accordance with an embodiment of the present invention andshowing the relation among the slots, fasteners, and wallboard

FIG. 5 is a side view of a portion of a structural wall assembly inaccordance with an embodiment of the present invention.

FIG. 6 is an end view of a portion of a structural wall assembly inaccordance with an embodiment of the present invention

FIGS. 7A-D are various end views of a portion of a structural wallassembly in accordance with different embodiments of the presentinvention

FIGS. 8-10 are various views of the fastening aspect of the presentinvention.

FIGS. 11A-C illustrates different embodiments of the present invention

FIGS. 12-13 illustrates different embodiments of the present invention.

DISCLOSURE OF THE INVENTION

The present invention provides for structural wall assemblies configuredto accommodate vertical deflections and horizontal drifts. In anembodiment, the present invention is directed to a metal framingstructural wall assembly that uses a simple fastener connection throughpreformed slots on both the U-shaped track and C-shaped studs. Thepresent invention also allows an installer to “adjust” stud flaming in ahorizontal direction without having to remove and reinstall fastenerswhen wall sheathing joints don't match up to the installed studs

For example, in current construction methods (accommodating the “growingor shrinking” of wall sheathing during application due to inconsistentwall sheathing widths or installed joints) the labor to unfasten, moveand refasten studs is both labor intense and time consuming. Thealternative of “adding” an additional stud in the cavity to create abacking element for wall sheathing edges which don't line up withattached framing is also labor intense and typically requires the “addedstud” to be additionally field modified (cut out) to accommodateexisting cavity obstructions such as pipes and wires installedhorizontally within the wall Such “cut” studs not only don't meet coderequirements but are also costly in both labor and material to install.

The present invention incorporates preformed slots of selected sizes andpositioned at specific locations such as (1) a horizontal slotpositioned on top and bottom tracks (allowing for horizontal movement ofthe stud and fastener) and (2) a vertical slot positioned on the studs(allowing for vertical deflection) with a fastener extending though bothslots. The present invention thus provides a simple and cost effectivemeans of reducing labor and materials.

The design having the slot located in the stud flange formed in a mannerwhich provides a connection that holds the fastener in place duringinstallation and also allows said fastener to be moved (vertically) withincreased pressure on the fastener (without damaging stud) and havingfastener held in “permanent” vertical plane or position by the tracksolves accommodating vertical deflection and permanent positiveconnection of the stud and track profiles.

The embodiments of the invention having an adhered or affixedintumescent as thick or thicker than a fastener head profile alsoprovides similar solutions for fire rated walls while providing sealingof joints from air, sound, smoke, fire, and thermal transfer between thewall sheathing and substrates as well.

Having horizontal slots in the track improves the short comings oftypical slotted track (multiple slots running vertically) by allowingstuds and fasteners positively attached via a fastener through a slot tobe adjusted horizontally during wall sheathing installation and alsoaccommodate horizontal drift movement. Slots formed in the stud profilesreceiving the shank portion of the fastener extending through the slotof the track and formed in a manner which creates a connection betweenthe stud and fastener supports the fastener from “pull out” while stillallowing and directing vertical deflection of the stud or substrate whenadditional pressure is applied from external forces with the fastenerbeing held in “stationary vertical position” by the u-shaped trackprofile.

In the embodiments including an affixed materials such as intumescentpositioned on the U-shaped track provides an air, smoke, sound, fire,and thermal seal or barrier for both non-rated and fire rated jointsbetween wall sheathing and substrates.

1. A U-shaped profile having a web surface and two leg surfaces affixedand extending in a perpendicular fashion with a minimum of one slotlocated through a minimum of one of the leg surfaces such that thelengthwise dimension is parallel the web surface and the width of theslot is less than the diameter of a fastener head having it's shankextending through the slot, preventing said fastener from passingthrough the slot, while allowing said fastener to move in eitherdirection parallel to the profile web.
 2. An embodiment of the inventionwith multiple slots or rows of slots located in one leg or both legs. 3.An embodiment of claim 1 having a minimum of one additional slot locatedin the web in which the lengthwise dimensions is perpendicular to theweb and leg intersection.
 4. An embodiment of claim 3 having multipleslots in the web.
 5. Said profile of claims 2 and 3 having opposingslots in opposing legs spaced apart and offset intermittently so thatopposing slots don't line up with one another but a slot is opposed byat least a portion of the solid surface spacing between two slots on theopposing leg.
 6. An embodiment of claim 1-5 having a material includingintumescent being as thick or thicker or thinner than a fastener headprofile providing sealing of joints from one or a combination of air,sound, smoke, fire, and thermal transfer between the wall sheathing andsubstrates affixed to the at least the outer surface of a minimum of oneleg with an adhesive, positioned between a minimum of one of the web andleg intersections and said slot(s) in the leg(s) for both non-rated andfire rated joints or walls
 7. Said material or intumescent of claim 6being similar or thicker than a fastener and creating an offset surfacea distance similar or thicker than said fastener beyond the leg outersurface.
 8. Said material and or intumescent of claim 7 having apolyester coating on the outer surface
 9. Said material and orintumescent of claim 7 or 8 wrapping around the web and leg intersectiononto a portion of an outer web surface.
 10. Said embodiments of claims1-9 having a minimum of one additional corrugation in a minimum of oneleg surface or having one leg “hemmed” at the end creating an offsetsurface distance from the outer leg surface that is the same or thicketthan a fastener
 11. Said embodiment of claim 10 having a minimum of onecorrugation in both leg surfaces or having both legs “hemmed” at the endcreating an offset surface distance from the outer leg surface that isthe same or thicker than a fastener.
 12. A C-Shaped profile having a webwith flanges extending perpendicular to the web and return flanges whichextend perpendicular to the flanges and parallel to the web and aminimum of one slot formed in a flange located proximate and end of aminimum of one of said flanges with said slot being of a width that isequal to or narrower than the outer dimensions of a smooth or threadedfastener shank such that when said fastener shank extends through saidslot at least the lengthwise edges of the flange which define said slotengage said fastener via contact with the outer edges of the fastenershank or threaded surfaces of a threaded shank creating a connectionsecuring said fastener from a “pull out” while still allowing thefastener to move in a liner direction defined by the slot when increasedpressure is applied to the fastener.
 13. An embodiment of claim 12 withsaid slot having “flared” edges directed inward towards the opposingflange such that the inward protruding longitudinal edges are spaced adistance apart that is equal to or narrower than the outer dimensions ofa smooth or threaded
 14. Said profile of claims 12 and 13 having singleor multiple slots located in a single or multiple flanges near a singleor multiple ends.
 15. Said profile of claims 12 and 13 having a minimumof one corrugation in a minimum of one flange and said slot locatedwithin a portion or exclusively through the corrugation surface. 16.Said profiles of 12 and 13 having an embossed pattern in the flange orweb surface areas.
 17. A wall assembly comprised of an embodiment of theU-shaped profile and an embodiment of the C-shaped profile with aminimum of one end of a C-shaped profile located between the legs of aminimum of one of the embodiments of the U-shaped profile, having amechanical or friction fit fastener located through a minimum of oneslot of a minimum of one U-shaped profile with the head of the fastenerproximate to the outer surface of the U-shaped profile leg outer surfaceand said fastener shank extending into a minimum of one said slot of aminimum of one C-shaped profile with the lengthwise edges of said slotin the C-shaped profile in contact with the outer or threaded surface ofthe fastener shank creating a connection with the shank or threadedshank of the fastener, said connection firmly connecting the fastenernot allowing it to “pull out” from installed position, with C-shapedprofile and fastener able to be move in a lateral (horizontal) directiondefined by the slot in the connected U-Shaped profile, with C-shapedprofile able to move in an up and down (vertical) direction defined bythe slot in the connected C-shaped profile with the fastener held inplace (from vertical movement) by the U-shaped profile.